Download - ESP1 Overview With Animation 08
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ESP System Technology Overview
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ESP Downhole SystemThe basic ESP downhole system components
are ...
The Monitoring System (optional)
The Power Cable
The Motor
The Seal Section
The Pump
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Product Identification Key
Equipment for 4.5 inch casing and larger
“300 Series”
SeriesDiameter model Type
338 3.375” D pump\seal
375 3.75” D motor
385 3.85” E pump
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Product Identification Key Equipment for 5.5 inch casing and larger
“400 Series”
Series Diameter model Type
400 4.00” F pump/seal
400 4.00” 400P Centurion Pump
450 4.50” F motor
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Product Identification Key
Equipment for 7.0 inch casing and larger
“500 Series”
Series Diameter model Type
513 5.125” G pump/seal
538 5.375” 538P Centurion Pump
544 5.438” G motor
562 5.625” K motor
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Product Identification Key Equipment for 8-5/8 inch casing and larger
SeriesDiameter model Type
675 6.75” H pump/seal
725 7.25” H motor
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Product Identification Key
Pumps only
SeriesDiameter model Minimum Casing
875 8.75” I 10-3/4”
900 9.00” N 10-3/4”
1025 10.25” J 13-3/8”
1038 10.38” M 13-3/8”
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Product Identification Key
Pump Stage Key
example 1: FC4300
F = 400 series, 4.00” pump
C = casting, S = synthetic impeller material
4300 BPD, best efficiency point (BEP) flow
except I and J pumps are in GPM
example 2: 538P17
538 = Series
P = Pump
17 = 17 hundred (1700) BPD @ BEP & 60 Hz
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Product Identification KeyModel Designation Key
1st Letter - Series D, F, G, K, H, I, J
2nd Letter - Product Type
P - pump, RS - rotary separator
S - seal, M - motor
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Product Identification Key
3rd, 4th, … Letters - Options, some of the most popular are …
LT - lower tandem, MT –middle tandem,
AR - abrasion resistant (pump),
X - corrosion resistant metallurgy, C - labyrinth type (seal),
M - modular AR style, C - ‘compression’ fixed impeller type (pump)
B - bag type (seal), G - high temperature option
B, C, E, F, H… in 3rd letter motor - rating ‘generation’
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LT = Lower Tandem pump
( with built in intake )
The seal bolts on here
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LT/MT = Lower/Middle Tandem pump
Head
Shipping Cap
If MT (middle tandem) or LT (Lower Tandem) then a flange face is the head of the pump.
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If FP type or Upper Tandem (UT) then a discharge is built into the pump.
FP Pump
Built in Discharge head
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Middle Tandem pump Base
UT or MT pump
Shipping Cap
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The Bolt on Head FPHVDIS
The Middle Tandem or Lower Tandem Pump Head
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Gas separator intake (cut away). May be bolted on to the base of a MT (Middle Tandem) or UT (Upper Tandem) Pump
The Seal bolts on here.
UT or MT pump bolts on here.
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ESP Downhole SystemThe system …
Should be set above the perforations of the well for unit cooling
Must be sized to the well’s productivity
Should be monitored for changes in well and/or unit performance
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The Pump Hangs from the production tubing
Lifts the fluid through the tubing to the surface
Is a multi-stage centrifugal type
Is constructed from impellers and diffusers
Must be sized to match the well production
Has an intake and discharge that either bolts onto or is threaded into the pump housing
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Built in Discharge head Tubing screws in here
Bolts to the Seal
Pump Shaft Built in Intake
Pump Housing
Rotating Impeller
Stationary Diffuser
The Pump
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Rotating (right to left) impellers
Stationary diffusers
Cutaway of Pump
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21Impeller
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Impeller
The impeller rotates about the pump axis, with the shaft
It provides the centrifugal force to the fluid - gives it energy.
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Impeller
Fluid enters the impeller through the ‘eye’ near the shaft and exits the impeller on the outside.
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24Impeller - Cut Away
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Impeller
Eye
Hub
Upper Shroud
Vanes
Lower Shroud
Skirt
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26Diffuser
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Diffuser
The diffuser does not rotate, it turns the fluid up into the next impeller
It transforms the fluid velocity, it’s energy, into head
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28Diffuser - Cut Away
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Impeller & Diffuser
Diffuser directs fluid into the eye of the impeller
Impeller spins and gives energy to fluid which exits around the outside
Diffuser redirects the fluid up into the next impeller and turns fluid energy into head
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30Impeller in Diffuser - A Pump ‘Stage’
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31Pump Stage - cut away
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Pump Stage
Fluid Reservoir
Developing the Pump Stage
Head – Capacity Curve
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Fluid Reservoir
Head (Lift)
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Developing the Pump Stage
Head – Capacity Curve
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The Seal Chamber Section Is located between the pump and motor
Transfers the motor torque to the pump shaft
Isolates (seals) the well fluid from the clean motor oil
Equalizes the internal unit and wellbore pressure
Provides area for motor oil expansion volume
Absorbs the pump shaft thrust load
The Four “Shuns” - expansion, equalization, isolation, & “absorbsion”
aka “Equalizer”, “Protector”, or “Seal Section”
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The Seal Chamber Section Is located between the pump and motor
Transfers the motor torque to the pump shaft
Isolates (seals) the well fluid from the clean motor oil
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MotorPump
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Motor
Pump
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Motor
Pump
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Motor
Seal
Pump
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42C en tr ilift
Located between the pump and motor
Transfers the motor torque to the pump shaft
The Seal Section
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Labyrinth Chamber
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Labyrinth Chamber
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Double Labyrinth Chamber
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The Seal Section, purpose:
1. Isolation Isolates (seals) the clean motor oil from the well fluid
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Isolation
Labyrinth Chamber
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Isolation
Prevents fluid migration down the seal shaft
Mechanical Seals
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Pump
Motor
Labyrinth Chamber
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Pump
Motor
Bag or Bladder
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Pump
Motor
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Isolation Bag (or Bladder)
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Isolation - Recap
3. Bag (or Bladder)
1. Labyrinth Chamber
2. Mechanical Seals
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The Seal Chamber Section Is located between the pump and motor
Transfers the motor torque to the pump shaft
Isolates the well fluid from the clean motor oil
Provides area for motor oil expansion volume
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Labyrinth Chamber
Motor Oil - Heated
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Labyrinth Chamber
Motor Oil - Cooling
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Double Labyrinth Chamber
Motor
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2. Expansion Provides space for motor oil expansion
The Seal Section, purpose:
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Expansion
Labyrinth Chamber
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Bag (or Bladder)
Motor
Motor Oil - Heated
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Bag (or Bladder)
Motor
Motor Oil - Heated
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Bag (or Bladder)
Motor
Motor Oil - Heated
Check valve
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Bag (or Bladder)
Motor
Motor Oil - Heated
Check valve
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Bag (or Bladder)
Motor
Motor Oil - Heated
Check valve
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Bag (or Bladder)
Motor
Motor Oil - Heated
Check valve
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79Motor
Motor Oil - Cooling
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80Motor
Motor Oil - Cooling
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81Motor
Motor Oil - Heated
Double Bags
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82Motor
Motor Oil - Heated
Double Bags
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83Motor
Motor Oil - Heated
Double Bags
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86Motor
Motor Oil - Heated
Parallel Bags
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87Motor
Motor Oil - Heated
Parallel Bags
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Expansion
Bag (or Bladder)
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Expansion - Recap 2. Bag (or Bladder)
1. Labyrinth Chamber
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The Seal Chamber Section Is located between the pump and motor
Transfers the motor torque to the pump shaft
Isolates the well fluid from the clean motor oil
Provides area for motor oil expansion volume
Equalizes the internal unit and wellbore pressure
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Motor
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92‘n’ thousand feet
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3. EqualizationEquals pressure between the outside casing and inside the motor housing
The Seal Section, purpose:
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r
Equalization 2. Bag (or Bladder)
1. Labyrinth Chamber
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The Seal Chamber Section Is located between the pump and motor
Transfers the motor torque to the pump shaft
Isolates the well fluid from the clean motor oil
Equalizes the internal unit and wellbore pressure
Provides area for motor oil expansion volume
Absorbs the pump shaft thrust load
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Compression, Fixed Impeller, Pumps
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Compression, Fixed Impeller, Pumps
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Motor
Seal
Pump
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Seal (Lower Chamber)
Motor
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Heat Exchange Area
Thrust Bearing Area
Seal (Lower Chamber)
Motor
Thrust Runner
Thrust Runner Carbon Face
Bearing
Bearing Retainer
Screen Filter
Upthrust Ring
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Seal Unit
Base
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Bearing Retainer
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Oil Pump
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Bearing
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Carbon
Face
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Thrust
Runner
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Thrust Runner Carbon Face
Thrust Runner
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Upthrust
Bearing
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Upthrust Bearing
Bearing Runner
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Bearing Assembly
Complete
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4. Absorption Absorbs the thrust of the pump
The Seal Section, purpose:
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Absorption
Thrust Bearingr
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The Seal Chamber Section Is located between the pump and motor
Transfers the motor torque to the pump shaft
Isolates the well fluid from the clean motor oil
Equalizes the internal unit and wellbore pressure
Provides area for motor oil expansion volume
Absorbs the pump shaft thrust load
The Four “Shuns” - isolation, equalization, expansion, & “absorbsion”
Or “Equalizer”, “Protector”, or “Seal Section”
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Seal Section Components - reviewMajor components are ... Mechanical Seals - prevents fluid migration down
the seal shaft
Bag(s) or Bladder(s) - provides expansion volume and isolation for clean motor oil
Labyrinth Chamber(s) - provides expansion and isolation volume in vertical or near vertical wells
Thrust Bearing - carries the thrust load of the pump shaft and stages (fixed impeller type only)
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Seal Section Application Use tandem seals in high pulling cost wells
– Seals are relatively low cost items as compared w/the total unit cost
– The more seal sections, the more mechanical seals and therefore, increased shaft isolation
– Can be designed as a “Thrust on Lower” (TOL) which gives added protection to the unit thrust bearing
Use single or multiple bag seals in highly deviated wells
– The isolation capability of a labyrinth chamber is greatly reduced in deviations beyond 30 - 45 degrees from vertical
Match the seal and motor series, when in doubt
– Provides for maximum oil expansion / reservoir volume
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The Motor Drives the downhole pump and seal section
Is rated for a specific horsepower, voltage, & current
Is a two pole, three phase, AC, induction type
Rotates at approximately 3500 RPM at 60 Hertz
Is constructed of rotors and bearings stacked on the shaft and loaded in a wound stator
Contains synthetic oil for lubrication
Relies on fluid flow past the housing OD for cooling
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Motor Components
Stator Laminations
Kapton-Wrapped Magnet Wire
RotorBearing with T-ring
Housing
Epoxy Encapsulation
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rotor
Bearing with T-Ring
Stator
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Stator Laminations on a Mandrel
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Stator Laminations pressed into the motor housing
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A wound Stator with Leads attached
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Potted End Turns
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Rotor Copper End Ring
Rotor Laminations
Rotor Bearing
Rotor T ring
Rotor Spacers
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Rotor Bearing
Rotor
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Motor Performance Motors are rated by horsepower, voltage, & current
At a constant voltage, by varying the pump load or brake horsepower applied to the motor, current will change
At a constant load, by varying voltage, current will vary, as well
By plotting the above parameters we can obtain two different series of graphs called motor composite curves
SPH, p. 48
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Motor Volts vs. Amps
Optimum Voltage
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Motor ApplicationMotor operating temperature is determined by 5 factors Wellbore Temperature
% Load vs. Nameplate Rating
Fluid Velocity Past Motor (flow rate vs. unit/casing diameter)
Cooling Properties of the Well Fluid (% gas, water cut, scaling tendencies, etc.)
Power Quality (3 phase voltage/current imbalance, wave form distortion, full nameplate voltage available, etc.)
All of the above factors determine if, and when, a motor will overheat during operation
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The Power Cable Is made up of the power cable and motor lead
Can be made in round or flat profile
Is constructed of three insulated & jacketed copper conductors contained by metal armor
Proper applications must address electrical, physical size, and operating temperature requirements
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Cable Types - Flat
Components1 - Conductor (Copper)
2 - Insulation (Polypropylene or EPDM)
(Ethylene Propylene Diene Monomer)
3 - Jacket (Nitrile or EPDM) & Tape
4 - Armor (Galvanized, Stainless, or Monel)
Benefits: Low profile to fit in tight clearance installations
2 4
3 1
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Cable Types - Round
Components1 - Conductor (Copper)
2 - Insulation Polypropylene or EPDM
(Ethylene Propylene Diene Monomer)
3 - Jacket (Nitrile or EPDM) & Tape
4 - Armor (Galvanized, Stainless, or Monel)
Benefits: Less current imbalance & runs cooler than equivalent flat cable
3 2
4 1
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Cable Types - Motor Lead ExtensionComponents1 - Conductor (Copper)
2 - Insulation Film (Polyimide)
3 - Insulation (EPDM)
4 - Jacket / Tape & Braid or Lead Sheath (Low Temp or Hi Temp)
5 - Armor (Low Profile Galv, SS, or Monel)
Benefits: Tape and braid provides added decompression resistance
1 2 3
5 4
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Cable Types - Extruded Barrier
Components1 - Conductor (Copper)
2 - Insulation (EPDM)
3 - Extruded Fluorobarrier (Low or Hi Temp)
4 - Jacket (Nitrile or EPDM)
5 - Armor (Galvanized, Stainless, or Monel)
Benefits: Unlike tapes, the barrier blocks fluid, aids decompression resistance, and improves electrical properties
1
24
5
3
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Cable Types - Lead SheathComponents1 - Conductor (Copper)
2 - Insulation (Polypropylene or EPDM)
3 - Lead Sheath
4 - Tape or Braid (on EPDM product only)
5 - Armor (Galvanized, Stainless, or Monel)
Benefits: Lead sheath blocks gasses & protects conductor from H2S attack
Available in round profile with EPDM jacket
2 5 4
3 1
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Cable Types - Capillary TubeFeatures & Benefits Available with any standard cable
A variety of capillary tube sizes are utilized
Available in round or flat profile
Allows targeted delivery of treatment chemical
Single or dual capillary designs
Instrument wire can be inserted in some capillary tube sizes
An outer layer of armor is applied to protect the capillary tubes
Standard Power Cable
Capillary Tubes
Capillary Tube
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Power Cable ApplicationProper application of ESP cable requires ... Limiting voltage drop to no more than 30 volts per 1000’ and less than
15% of motor volts by choosing a sufficiently large conductor (AWG) size
Choosing the proper profile based on tubing thread size vs. casing ID & conductor size
Selecting a cable type based on operating conductor temperature &/or other wellbore factors, e.g., presence of H2S, high gas, etc.
SPH, pp. 100-102
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Poly Cable KV Rating
3 KV
4 KV 5 KV
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The Monitoring System Various downhole monitoring units can be attached to
the bottom of the motor &/or deployed separately in the wellbore
Signals are either impressed (DC) on the power cable or sent via separate instrument wire
Available monitoring options include …
– Pump Intake Pressure
– Motor Operating Temperature
– Discharge Flow Rate
– Discharge Pressure
– Unit Vibration
– Future -- Fiber optics
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The Surface EquipmentThe surface equipment (beyond the wellhead)
consists of …
The Motor Controller
The Transformer(s)
The Junction or “Vent” Box
Wellhead
Surface Cable
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The Controller SystemThe two types of controllers used with ESP systems
are … Switchboards (fixed speed)
Variable Speed Controllers (aka “drives”)
Both types of Controllers can be made to read monitoring system output signals
Both types generally require transformers to convert the supply or output voltage to the required unit voltage
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The SwitchboardFeatures
Applies full voltage and current to the downhole system on start up (aka “across the line” starting)
Utilizes a motor controller unit for system protection and monitoring
Is hooked to transformers which convert the incoming voltage and current to the required voltage and current for the ESP system
Disadvantages
Starting across the line results in extremely high mechanical and electrical stresses on the system
Does not allow pump-well mismatch or fine tuning which results in unit cycling
Flow control can only be accomplished with a surface choke which may result in the pump operating outside of its recommended range
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The Motor ControllerThe motor controller … Is the “brains” of the switchboard
Monitors incoming voltage and current to the downhole system
Can be set up to allow automatic restart under certain conditions
Protects the motor from voltage and current fluctuations and imbalance
Some models have RTU communication & data logging capability
Has auxiliary inputs for the various monitoring signals
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The Variable Speed ControllerFeatures & Benefits Allows fine tuning of unit performance to the well which
can increase efficiency & minimize unit cycling
Soft starts the unit which reduces system mechanical and electrical stresses
Protects the downhole equipment from under & over current as well as voltage unbalance and transients
Delays pull and resize of equipment to restore production rate due to wear
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Graphic display Interface
The VSC Graphic Control System
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GCS Main MenuGCS Main Menu
The organization of parameters and information is common for the 9 main menu options on all GCS products.
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GCS Status ScreenGCS Status Screen
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The TransformerThe transformer … Converts supply voltage and current to a level at or near
the required system voltage and current
Has multiple tap settings for flexibility
Must be of a special design to work properly with VSCs
Should be sized to be greater than or equal to the required total KVA of the downhole system
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The Junction BoxThe Junction Box … Provides the main contact point between the downhole
unit cable and the surface equipment cable
Provides a point of separation to determine downhole or surface electrical faults
“Vents” gasses that escape through the cable insulation and jacket in certain low pressure wellhead designs